Method and apparatus for producing bodies formed of separate fibers



. 1,643,505 P 1927' H. B. LINDSAY METHOIYAND APPARATUS FOR PRODUCING BODIES FORMED OF SEPARATE FIBERS v 1 20 Filjgdid an. 9,. 1925 5 3 Sheets- Sheet 1 l I .14 J 1 nnuuuuuunnun mm 1,643,505 S p 1927' H. B. LINDSAY METHOD AND APPARATUS FOR PRODUCING BODIES FORMED OF SEPARATE FIBERS Filed Jan. 9. 1925 w s Sheets-Sheet 2 1,643,505 SePt- 1927' H. B. LINDSAY METHOD AND APPARATUS FOR PRODUCING BODIES "ORMED 0!? SEPARATE FIBEBS Filed Jan. 9. 17925 3 Sheets-Sheet 3 Patented Sept. 27, 1927.

UNITED STATES 1,643,505 PATENT OFFICE.

HARVEY B. LINDSAY, OF OAKLAND, CALIFORNIA, ASSIGNOR-TO DRY ZERO CORPORA- TION, OF WILMINGTON, DELAWARE, A, CORPORATION OF DELAWARE.

METHOD AND Application filed January My invention relates generally to the producing of bodies, such as thermal insulating bodies and cushioning bodies, such as for example bedding mattresses, carpet cushions and upholstery, formed of separate fibers;

and, as to one aspect thereof, to the pro- 4 ducing of such bodies from relatively highly compressed bales of fiber, as for example, and more'particularly, 'kapok fibers; as to another aspect thereof, to the forming of such bodies of substantially the same density throughout their extent; and, as to still another aspect thereof, to the'production of such bodies with a complete, or partial, enclosing covering; this application, in part, being a continuation of my application for U. S. Letters Patent Serial No. 683,087, filed December 27, 1923. I

As a preface to the following, and as bearing upon one aspect of my invention, it may be stated that it is highly desirable, the fibers of the compressed bale, and especially in the case of kapok, be separated from the bale with the minimum impairment of the fibers as by crushing, tearing or fracturing, this being of importance not only where a body for thermal insulation is'to be produced, but also in the case of the producing of a cushioning structure or body.

Referring to the matter of the provision of the body for thermal insulation purposes it may be stated that according to my demonstrated theory of thermal insulation, transmission of heat through a body composed of separate fibers is governed to a large extent by the degree of microscopic smoothness of those surfaces of the fibers which extend crosswise ofsthe path of heat transmission,- and this is due. to the action which takes.

place in such a'body wherein the external surfaces of the fibers. as also the internal surfaces thereof when of tubular form, are subject to the bombardment of the rapidly moving gaseous atoms where the insulating material is subjected to heat traversing the air to which the fibers are exposed. These gaseous atoms being heated their external electrons are under violent agitation and transmit. through such agitation. violent agitation tothe external electrons of the molecules of the fibers proportional to the length of time they. are in contact with'the latter, and the converse is true where the fibers are in heated condition, in which case APPARATUS FOR PRODUCING BODIES FORMED OF SEPARATE FIBERS.

9, .1925. Serial No. 1,509.

the external electrons of the molecules of the 4 fibers are in violent agitation and transmit suchagitation to the electrons of the gaseous atoms proportional to the length of time the electrons'of the molecules of the fibers so violently agitated arein contact with the electrons of the gaseous atoms.

Where the surfaces of the fibers are relatively rough and therefore present microscopic crevices, depressions or projections, the gaseous atoms bound and rebound against the surfaces of such irregularities before escaping, and with each impingement the agitated electrons 'ofthe hotter element react on the relatively quiescent electrons of the cooler element, conveying their excess agitation to the latter and thereby transmitting heat. Thus, the smoother, and the less crushed or fractured, the surfaces of the fibers, the less the rebounding of the moving electrons and consequently the less transmission of heat. It is, therefore. desirable to employ fibers having smooth. unimpaired, surfaces, and .it is also desirable that the fibers be free of kinks.

As regards the provision of a cushioning body or structure, as (for example) in the case of a mattress. a carpet cushion or a body of upholstering, the resilience and the lasting qualities of the body or structure are reduced proportional to the amount of short and-crushed or cracked fibers forming the body and thus it is desired that the fibers in the operation of separating them from the bale and delivering them to the point of assembly to form the body, he maintained unimpaired 'to as great an extent as possible.

My objects generally stated, are to provide for the separatingof the fibers from the bale, with the minimum impairment of the fibers; to provide for the production of a body. of the character above stated in quilted or mattressed condition; to provide for the producing of the body. or structure, preferably quilted, or tinuous operation producing the article to be formed. in a continuous length, or in any predetermined length; to provide for the production of a body of such material of substantially uniform density; and other objects as will be manifest from the following description:

Referring to the accompanying drawings:

mattressed, by a conproduced is formed,

- mg frame 19, f l y the-medium of flabelt20 driven from any j suitable source. f

Figure 1 is a plan view, with certain portions omitted, of an apparatus constructed in accordance with my'invention and adapt ed for the practicing of my improved method. Figure 1 is a simi r view, with certain parts broken away, of that part of the apparatus which is omitted in Fig. '1. Figure 2 is an enlarged broken view in vertical section taken through the formerportion of the apparatus, the section being taken at the line 2 on Fig. 1 and viewed in the direction of the arrow. Figure 3 is an enlarged broken sectional view taken at the line 3 on Fig. 1. and viewed in the direction of the arrow. Figure 4 is aview in side elevation of the apparatus shown in the preceding figures. Figure 5isan en larged sectional view taken at the line 5 on Fig. 1 and viewed in the direction of the arrow. Figure 6 is an enlarged sectional view taken at the line 6 on Fig. 1 and viewed in the direction ofthe arrow. Figure 7 is a plan sectional view of the tumbler portion of the apparatus. the section being taken at the line 7 0n.Figs.'5 and 6, and viewed,

in the direction of the arrow. Figure 8 is an enlarged sectional View of the measuring device of the apparatus. the section being taken at the line 8 on Fig. 1, and viewed in the direction of the arrow. Figure 9 is measuring devlce represented generally at- 34. The measuring device 34 which is proa broken sectional view taken at the line 9 on Fig. 1 and viewed in the direction of the arrow; and Figure 10. a broken perspective view of the body or structure produced by the apparatus- 4 Referring to the particular illustrated apparatus it comprises a device, represented generally at 15, for subjecting the bale of fiber from which the body is to be formed,

to such an action thatthe fibers thereof will 7 be loosened from each other at the outer surface of the bale for movement to the part of the apparatus in which the body to be and without tearing or brea'kingthe fibers.- The device 15 which operates by a tumbling action comprises a tumbler drum 16 shown as of cylindrical form nounted at circular. circumferentially disposed-tracks 17 thereon, on rollers 18 ournaled in spaced relation on a supportthe drum 16 being driven in suitable manner, as for example through 'The'drum is provided about its inner surface'with a plurality of bathe-forming ribs 2 which extend lengthwise of the drum J} m preferably substantiallv' equidistantly spaced"relation, as shown (Fig. 6). The

ends' 22 and 23 of the drum contain cen-' trally-disposed openings 24 and 25,, respec-] tively, the

opening 24, in the particular arrangement shown communicating with the atmosphere, serving to permit of flow of air into the drum through this end thereof and under the action of suction applied to the opening 25, as hereinafter described, and producing air gurrents'f'in the drum which entrain the separated .fibers and conduct them out of the drum. The drum is preferably several times as long as a bale of the material to be op'erated'upon and contains at itsoutlet end" open-work" barriers represented generally at 26 spaced-apart lengthwise ofthe drum, each of, these barriers being shown as formed of twogenerally triangular portions 27'and 28 arranged relative to each other as shown in barriers serving to prevent the bale, or heavy masses of the fibers, from moving in the drum to a position in which they'int'erfere with the desired freedom of movement of the air. and the fibers entrained therein, through the outlet 25. The municates, through the medium of a revolvoutlet 25 com- Fig. 5, these ing joint conduit 29, with the inlet of a SLIClZlOnblQWBI represented at 30 which may be of any desirable construction, as by way of example of the centrifugal type, the conshown generally at 32 communicates with the inlet end of an outwardly flaring coriduit 33 which opens atits outlet into a vided for'the purpose of ensuring'substantially uniform flow of the fiber to the former-device, hereinafter described, com-,

prises a cylindrical housing 35 containing openings 36 and 37 in its circumferential side-wall which extends substantially the full length of the latter and and an outlet, respectively, for the housing, the inlet 36 communicating with the conduit 33. Located within the housing 35 and concentrically disposed relative'to the latter and in spaced relation thereto, is an innershell 38 provided with an inlet and an outlet 39 and 40. respectively, vwhich extend substantially the full length of the shell and in registration withthe inlet and outlet 36 The housing 35- and shell 38 are supported at their ends on a shaft 41 fixed in the upform an inlet 37, respectively, ofi the housing 35.

per ends of stationary brackets one of which w is represented at 42, .the ends of the shell 38 being securedto the shaft 41-as by set screws, as shown of the set screw 43 ii Fig. 9. The measuring device also comprises a rotatable interstitial drum structure represented generally at 44 and lpcated within the annular space between the shell 38 and the housing 35, the device 44 comprising a cylindrical sidewall-forming por- I tion 45 of interstitial; form, it being preferably formed, of wire'mesh. The endsof the drum 44 comprise rings 46 connected, and

extending concentrically, with the cylindria cal portion 45 of the drum 44, these rings projecting radially outwardly beyond the portion 45 and being connected with the outer ends of spokes 47 connected with hub portions 48 rotatably mounted on the ends of the shaft 41 bet-ween the end walls of the shell 38 and the end walls'of the housing 35. One of the hub portions 48 is shown as provided with a pulley 49 driven from any suitable source, and'through the medium of which the drum structure 44 is iotated in the direction of the arrow in Fig 8. The hubs 48 extend between the shaft 41 and openings in the ends of the housing 35 as shown of one end of the structure in Fig. 9, and means, represented at 50,

are provided for-rigidly connecting the housing 35 to the brackets '42. The drum structurew44 also comprises a plurality of radially-disposed parallel fins 45 provided in a series about the circumference of the side-wall portion 45 andwXtendfng within the space defined by the side walls of the housing 35 anddrum-portion 45 and the rings 46, these fins which extend parallel with the axis of the drum portion 45 and are preferably equidistantly spaced apart and extend from one ring 46 to the other thereof and clpse to the inner circumference of the side wall of the housing 35, being preferably of interstitial form, preferably of wire-mesh construction.

- interstitial and leaving the shell 38at its outlet 40; and

' that thevolume of fiber (carried by said air currents which 'will be discharged from this device', can be governed by the speed of rotation of the drum.

,The outlet 37 of-the measuring device communicates with the inlet of- .a conduit 51 the outlet end of which, and forming a nozzle, extends loosely intothe' former, hereinbefore referred to, and represented at 52.

' The outlet portion of the nozzle 51 is of shown-in Figs. 1 and 3.

general rectangular shape in cross section with its side walls, represented at 53, preferably extending entirely through the former 52 which is likewise of rectangular shape in cross-section. The upper and lower walls 54 and 55, respectively, of the nozzle reach short of the outer ends of the walls 53 and terminate a short distance beyond the ex treme forward edge of the former 52 as In other words, the upper and lower walls of the former 52 overlap the corresponding walls of the nozzle and extend .in spaced relation thereto as shown in the drawings. The inside cross cloth fabric,-to be positioned at opposite.

sides of the fiber bodyrp'roduced in the former 52, these means comprising stand 2!?(1559 von which the former 52 ism'ounted,

located at opposite sides of the apparatus and containing notches 60 and 61 in which the ends of the cores 62 and 63 carrying the sheet material 58 are seated for rotation, these notches being disposed, respectively, above and below the plane occupied by the former 52.

The sheet material 58, which, in the particular arrangement shown, is of a width considerably greater than the width of the outlet end ofthe nozzle 51, extends from the rolls thereof into the former 52 .atthe upper and lower portions of the'latter and into the spaces between the upper and lower walls of the former 'and the corresponding .walls of the nozzle, as shown.

-Located beyond the former 52 are feeding means comprising two sets of feed rolls represented at 64, 64 65 and 65, journaled at their ends in frame works '67 at opposite sides of the apparatus, these sets of rolls being spaced apart length-wise of the apparatus and the rolls of each set thereof be ng respectively disposed above and below the formed body and the upper and lower envelope (material. The upper rolls, as shown, are drive rolls having drive connection therebetween as by means of sprpcket 68 and 69 on the rolls and a sprocket chain 70 engaging these sprockets, driving power being applied to one of the upper rolls, as

through the medium of a belt pulley 71 on the roll 65. Y I g The rolls 64, 64, 65 and 65, are alike as to form and size, each. preferably presenting at its. ends, laterally beyond the side walls 53 ofthe nozzle 51, circular disklike portions 72 which are so spaced apart as to firmly grip between them the lateral edges of the sheet material 58 which extend laterally beyond. the side walls 53 of the nozzle. -The portions of the rolls intermediate the disk-like portions 72, and indicated at 73, are of such reduced diameter that they are spaced apart a distance suflicientiy less than the thickness of the body produced in the former 52, and comprising the mass of fibers and the superposed and formed of the mass of fibers and the covering material 58 and also for sewing together the lateral edges of the covering material 58, these means being represented generally at 74 and comprising a plurality of stitchers, represented at 75 which may be of any flatwise condition, the lateral edges of the suitable construction, such as are commonly used in the manufacture of stitched pads of various kinds, and sewing devices located in line with the disk-like portions 72 at opposite sides of the apparatus and represent-. ed at 76, these devices being of any desir-- able construction for sewing together in sheet material 58.,

A description of the operation of the il-' lustrat-ed apparatus is as follows:

Assuming a bale of fiber is introducedinto the tumbler device 15 the'operation of the suction blower 3O draws the fibers, separated from the bale by the tumbler action, out of the drum 1-6 and thence into the blower from which they are discharged into the con-' duit 33 and into the compartments presented above the periphery of the interstitial drum 44 in which "compartments the fibers become deposited. By the rotation of the drum 44 the fibers in these compartments, when the latter, inthe rotation of the drum;'move to a' position in which they register with the outlet of the 'inner shell 38, are blown, by the air-blast'entering the shell 38 through the inlet 39, outof these compartments and into as nozzle 51 andthenceinto the former 52 wherein the fibers become massed into a body within the space defined by the side walls 53 of the nozzle and the sheet material 58, asshown in Fig. It may be here stated that in the initial starting of the apparatus a barrier would beplaced across the rear end of the'former 52 adjacent the ex-' tremities of the walls 53 of the nozzle against which the fibers firstblown into the former would impinge, in order that a body of the 'fiber maybe built up. Thereafter the feed.

mechanism and the stitching and sewing mechanism, hereinbefore referred to, will be set into operation-to feed the bodycomposed of the mass of fibers and the sheet material,

, to carry out of theformer and upon a table represented at 77,. the assembled. mass of fibers and sheet material and stitch or tuft the same to the condition shownin Fig.

a conveying current of air.

2. In the producing of a body of. ma-- 10, the operation of producing thebody or structure being thereby'rendered continuous. It is necessary that the air carrying the fibers into the former 52, be relieved from the former 52 after depositing the fibers therein, and this is accomplished by providing vents in the former formed by preference in both the top and bottom wallsof the former 52, the openings in the top wall thereof being represented at 78, it being understood that the air escapes through the sheefmaterial 58 and thence through the openings 78. I

Where the product of the apparatus is to be used for thermal insulation it is desirable that the mass produced comprise for each cubic foot thereof approximately one pound of the fibers and accordingly the speed at which the various mechanisms described are driven should be regulated.

The provision of the measuring device described is of advantage as thereby a uniform How of fibers to the former 52 producing a uniformly dense mass of the fibers in the latter, may be effected for any width or size of the body to be produced, as thevolume of fibers delivered to the nozzle can be governed by the speed at which the drum of the measuring device is rotated.

The subjection of the bale of-the fiber to the tumbling action described results not only in the rapid removal of the fibers from the bale, but effects such removal with the minimum danger of impairment of the fibers with the advantage above noted. a i

It may be stated that kapok fibers, which are extremely light and fine, are peculiarly amenable to the treatment above set'forth. However, the treatment referred to is useful .in the treating of other fibers in approxi mateproportions to their relative weight, the

heavier andcoarser the fibers the greater the. degree of, refractoriness.

While Ihave illustrated and :described a.

particular construction of apparatus e'm-.. bodying my invention and have described my improved method as practiced by a particular apparatus, I do not wish to be under.-

stood as intending to limit my invention thereto. as the'apparatus may be variously modified and altered and other apparatus employed, without departing from the spirit of my invention.

What I claim as new, and desire to secure r by Letters Patent, is

1. 'In the producing of. a body of material formed ,of separate fibers, the subjecting of a compressed bale of the fibers to a tumbliii action for loosening the fibers therefro and the subjecting-of the loosened fibers to terial formedofseparate fibers, the subjectmg of a compressed bale of the fibers to a tumbhng action for loosening the fibers therefrom and the subjecting of the loosened fibers, simultaneously with the tumbling action, to a conveying current of air.

3. In the producing of a body of material formed of separate kapok fibers, the subjecting of a compressed bale of the fibers to a tumbling action for loosening the fibers therefrom and the subjecting of the loosened fibers to a conveying current of air.

4. In the producing of a body of material formed of separate kapok fibers, the subjecting of a compressed bale of the fibers to a tumbling action .for loosening the fibers therefrom and the subjecting of the loosened fibers, simultaneously with the tumbling action, to a conveying current of air.

5. The method of decompressing a comressed bale of fibers which consists in repeatedly bodily raising and dropping the bale to loosen its fibers and removing the loosened fibers at the surface, of thebale by subjecting the fibers to a current of air.

6. In a tumbler device, the combination of a rotatably mounted drum containing in- 'wardly projecting portions and an inlet and an outlet for air, the outlet for air being in an end wall of said drum, and means in said drum extending transversely thereof for maintaining the bale to be tumbled at all times in spaced relation to said outlet.

7. In a tumbler device, the combination of a rotatably mounted drum containing inwardly projecting portions and an inlet and .an outlet for air, the outlet for air being in an end wall of said drum, and means in said drum extending transversely thereof for maintaining the bale to be tumbled at all times in spaced relation to said outlet,

the effective cross-sectional area of draft atsaid means being greater than at said outlet.

8. In a tumbler device, the combination of a rotatably mounted drumflconta'ining inwardly projecting portions .andan inlet and an outlet for air, the outlet for air being in an end wall of said drum, and an open-work barrier in said drum and extending transversely thereof for maintaining the bale to be tumbled at all times in spaced relation to said outlet.

9. In apparatus of the thecombination of a conduit, a former device communicating with said conduit, means for subjecting fibers, supplied to said conduit, to conveying currents of air, and means in said conduit for measuring and controlling the supply of fiber to said former device, controllable to var the volume' of fiber per unit of time owing to said device.

10. In apparatus of the character, set forth, the combination of a conduit, means for supplying air under pressure to said conduit for conveying fibers therethrough, a former device communicating with said conduit, and

character set forth,-

and controlling the amount of fiber delivered to said former device.

12. In apparatus of the character set forth, the combination of a conduit, a former device communicating with said conduit, means for causing fiber-conducting currents of air to flow through said conduit to said former device, and a measuring device for measuring and controlling the amount of fibers passing through said conduit to said former device. In apparatus of the character set forth, the combination of a conduit, a former device communicating with said conduit, means for causing fiber-conducting currents of air to flow through said conduit to said former device, and a measuring device for measuring and controlling, and regulable to vary, the amount of fibers passing through said conduit to said former device.

14. In apparatus for the purpose set forth, the combination of a conduit, a former device communicating with said conduit, means for subjecting fiber, supplied to said conduit, to conveying currents of air, and means in said conduit for measuring and controlling the supply of fiber to said former device controllable to-vary the volume of fiber per unit of time flowing to said device comprisfioW through the course provided'by said conduit and housing. v

15. In apparatus for the purpose set forth,

the combination of a conduit, a former de- I vice communicating with said conduit, means for subjecting fibers, supplied to said conduit, to conveying currents of air, and means in said conduit for measuring and contrdlling the supply of fiber to said former device controllable to vary the volume of fiber per unit of time flowing to said device comprising a housing containing an inlet and an outlet, said conduit communicating with said inlet, an interstitial rotatable drum located in said housingbetween said inlet and outlet and provided circumferentially with fins spaced apart to form compartments, and means for causing fiber-conducting current by said conduit and housing.

of air to flow through the course provided 16. -In apparatus for the purpose set forth, the-combination of a conduit, a former device communicating with said conduit, means for subjecting fibers, supplied to said conduit, to conveying currents of air, and means in said conduit for measuring and controlling the supply of fiber to said formerdevice controllable'to vary the volume of fiber per unit of time flowing to said device comprising a housing containing an inlet and an outlet, said conduit communicating with said inlet, an inner shell spaced from said housing and containing an inlet and an outlet substantially registering, respectively, with the inlet and outlet of said housing, an interstitial rotatable drum located in the space between said housing and shell and provided circumferentially w1th fins spaced apart to form compartments, and means for causing the fiber-conducting currents of air to flow through the course provided bysaid conduit and housing.

17. In apparatus of the character set forth, the combination of a conduit, a formerdevice communicating with said conduit, means for subjecting fibers, supplied to said conduit, to conveying currents of air, and rotatable means in said' conduit operating in their rotation to measure and control the supply of fiber to said former device.

' 18. The method of producing a body formed of fibers and of substantially uniform density, which consists in producing a measured flow of fiber'to the point at which thebody is to be formed by delivering the bers, by theaction of an air current, to a rotatable.interstitialcarrier and removing the fibers therefrom by the action of an air current, after the drum has made a partial revolution.

v HARVEY B. LINDSAY. 

